TIG Welder Consumables

TIG welding consumables come in a variety of types and sizes, dependant on the type of material you’re welding and its size (thickness). Then there’s the individual differences. i.e. If you’re purchasing back caps, they can be supplied as small, medium or long.

The consumables can also be split into three distinct groups:

  • Filler Wire (or Rods).
  • TIG Torch Parts and Accessories.
  • Shielding Gas.
Note:
TIG Welding Consumables

Topics on this Page:


TIG Welding Consumables (General Information):

There are many parameters you need to consider when buying TIG consumables.

TIG Consumables – Gas Cups, Gas Nozzles & Collets – The Same Size, But Different Types:
  • The type of material(s) to be welded.
  • The thickness of the material to be welded.
  • The filler rods and their compatibility.
  • The type of welded joint.
  • The different variations of the interchangeable ‘consumable’ parts (and do they fit the torch?).
TIG Welding – Material Thickness, Current, Consumable Sizes (A rough guide):
TIG Welding – Consumable Cross Reference Guide1
Material Thickness Amps Size (mm)
mm Inch Gauge DC AC Filler Rod Tungsten Gas Cup
0.50 1/64 24 5-20 5-15 1.02 1-1.6 3-5
0.65 1/32 22 10-35 10-30 1.02 1-1.6 3-5
0.80 1/32 20 20-50 25-45 1.02 1-1.6 4-5
1.00 3/64 18 25-80 45-60 1.0 1-1.6 4-5
1.30 3/64 16 40-90 50-100 1.0 1.6 4-6
1.60 1/16 14 60-100 50-100 1.6 1.6 4-6
2.40 3/32 11 85-125 90-150 1.6-2.4 1.6 4-6
3.20 1/8 100-135 125-190 1.6-2.4
2.4 4-6
4.00 5/32 125-175  180-200  2.4 2.4 5-7
4.80 3/16 150-225 180-240 3.2 2.4 7-8
This is only a guide, please refer to the manufacturers data sheets.
Reference:
  • 1 Due to the many different parameters (the type of material, its size, the type of joint, etc, etc), the table above should be considered as a very rough guide:
  • 2 Tig filler rods are generally sold in sizes from 1.0mm and upwards (aluminium 1.6mm). If you want a smaller size wire, MIG wire is often used.
Notes:
  • Always follow the manufacturer’s warnings, instructions, and their Material Safety Data Sheet (MSDS). Welding fumes and dust can affect your health.

Which Consumables Fit my TIG Torch?

There range of consumables can be purchased in different sizes, configurations, types and for different materials! Therefore, it’s important to know which parts you want. The links below give more detailed information on all the different types of part (consumables) available and the various different configurations…

As an illustration:

TIG Welding Torches (Guns) – Fittings Compatibility
Cooled by: TIG Torch Gas Cup Thread Gas Nozzle
Torch Thread
Back Cap
Type1 Fittings Group Standard2 Stubby2
Air WP-9 A 3/8in UNF 9/16in UNF 5/16in UNF 5/16in UNF
Water WP-20
Air WP-17 B 13/32in UNS 3/4in UNF 3/8in UNF 3/8in UNF
Water WP-18
Air WP-26
This is only a guide, please refer to the manufacturers data sheets.

The Different Consumables (In more detail):

The topics listed below, will hopefully make it easier to understand what the differences are between the various TIG welding consumables, and make it easier to obtain the correct items for the job in hand.

The three distinct groups of TIG consumables: (links open in a new tab)…

1. TIG Filler Wire (or Rods):
2. TIG Torch Parts and Accessories (Consumables):
3. TIG Shielding Gas:

TIG Filler Rods (Filler Wire)

Topics: The Different Types of TIG Filler Rods (An Overview):TIG Wire Rod (Filler Wire) Sizes:Image Gallery: The Different Types of TIG Filler Rods (An Overview): As with all the other […]

TIG Shielding Gas:

Welding gases provide a shield around the welding arc to prevent oxygen, nitrogen and hydrogen (contained in the air around us) from affecting the quality of the weld. Topics: The […]

TIG Tungsten Electrodes:

Tungsten electrodes come in a variety of types and sizes. Which Tungsten electrode you use, may be dependant on what you want to weld? Here is a list of the […]

TIG Gas Cup:

TIG Gas Cups – Names Used: Consumable Names Used TIG Gas Cup Gas Cup Ceramic Cup Shroud Cup Nozzle1 1The name ‘Nozzle’ is sometimes used for the TIG gas nozzle. […]

TIG Heat Shield (Insulator):

The TIG insulator (heat shield) often gets overlooked. But it is often designed to match the type of ceramic cup being fitted. You can use different insulators with different types […]

TIG Gas Nozzle (Collet Body or Gas Lens):

The shielding gas exits the gas nozzle (gas lens) and fills the gas cup that screws over and surrounds the gas nozzle. TIG Gas Nozzle – Names Used: Consumable Names […]

TIG Collets:

A collet holds the Tungsten electrode. When you screw on the back cap, it pushes the collet against the gas nozzle, which squeezes the collet jaws. This makes a good […]

TIG O’Rings:

TIG torch o’rings, are normally found in two places: On the back cap, where it screws into the TIG gun body (to provide a shielding gas seal).On a glass gas […]

TIG Back Caps:

A TIG back cap is an insulator and: Provides protection against shorting out the Tungsten electrode that sticks out the back of the TIG torch.Provides a gas tight seal to […]

TIG Welding Gun (Torch) Parts:

A TIG gun (torch) can have various interchangeable parts fitted. These interchangeable parts (along with the TIG welder controls), enable you to weld a variety of materials, and their different […]

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